E Programmable Controller Coupler (IMPCC01) Operation/Configuration Manual

Transcription

1 E96- Programmable Controller Coupler (IMPCC0) Operation/Configuration Manual

2 Preface The Programmable Controller Coupler module (IMPCC0) provides a convenient means of reading data values from a programmable controller into INFI 90 OPEN function blocks and writing INFI 90 OPEN function block values into a programmable controller. With an appropriate communication adapter, the PCC0 module supports data communication with: Allen-Bradley PLC-, PLC-, PLC-5 and PLC-5/50 via Data Highway I, Data Highway Plus or Data Highway II. Modicon 584 and 984 controllers via Modbus (RTU mode). Programmable controllers that have support for Modbus (RTU mode) communication. G.E. Series-5, Series-6 and Series 90/ 70. Controller by Siemens, Relience, and others. This instruction manual describes the module s communication capability and explains how it can be configured for a specific programmable controller (entirely through function block configuration). I-E96-D

3 List of Effective Pages Total number of pages in this instruction is 00, consisting of the following: Page No. Change Date Preface Original List of Effective Pages Original iii through ix Original - through -5 Original - through -5 Original - through - Original 4- through 4- Original 5- through 5-4 Original A- through A-9 Original B- through B-4 Original C- through C-9 Original D- through D-7 Original Index- through Index- Original When an update is received, insert the latest changed pages and dispose of the superseded pages. NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer margin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the outer margin next to the figure caption. The date the update was prepared will appear beside the page number. I-E96-D

4 Table of Contents Page SECTION - INTRODUCTION... - OVERVIEW...- PROGRAMMABLE CONTROLLERS SUPPORTED...- HARDWARE NEEDED TO SUPPORT THE IMPCC0...- MEMORY AND TIME RESPONSE CAPACITY SPECIFICATIONS...- SOFTWARE SUPPLIED ON THE DISKETTE INCLUDED WITH THE IMPCC CONTENT OF THIS MANUAL...-4 RELATED DOCUMENTS...-4 FREQUENTLY USED TERMS...-5 SECTION - DESCRIPTION... - OVERVIEW...- GENERAL INFORMATION...- TRANSACTION DATA FIELD SIZE DETERMINATION...- PROGRAMMABLE CONTROLLER ANALOG DATA FORMAT/CONVERSION...- DIGITAL AND ANALOG WRITE GROUPS INITIAL DATA...- WRITE GROUP BLOCK OUTPUT BAD QUALITY HANDLING...- REDUNDANT MODULES STANDBY TAKEOVER...-4 ERROR REPORTING METHODS...-4 SECTION - HARDWARE INSTALLATION AND SETUP... - GENERAL INFORMATION...- PCC0 MODULE INITIALIZATION...- SERIAL RS SIGNAL TERMINATION...- SECTION 4 - CONFIGURATION GENERAL INFORMATION...4- FUNCTION BLOCKS...4- SETTING UP THE DATA TRANSFER GROUPS...4- Data Link Boundaries...4- Critical PCC0 Configuration Run Time Considerations PC Data Addressing Allen-Bradley PLC Allen-Bradley PLC Allen-Bradley PLC Allen-Bradley PLC 5/ Modbus Protocol BASE BLOCK CONFIGURATION COMMON COMMUNICATION DEFINITIONS Block 5, Segment Control Block Block 0, PC Device Type (FC 5, Non Tuneable) Block, PC AB Data Highway II Link Address (FC 5, Non Tuneable) Block, PC AB Data Highway II Node Address (FC 5, Non Tuneable) Block, PC Device Station Address (FC 5, Non Tuneable) Block 4, PC Port Communication Parameters (FC 5, Non Tuneable) Block 5, Diagnostic Port Communication Parameters (FC, Tuneable)...4- Block 6, Error Trigger Block Number (FC 9, Non Tuneable)...4- Block 7, Write Permissive (FC 9, Non Tuneable)...4- Block 8, Diagnostic Output Enable (FC 50, Tuneable) Disabled = 0, Enabled =...4- Block 9, PC Register Value Format (FC 5, Non Tuneable)...4- Block 40, Maximum Transmit Capacity (Bytes, FC 5, Non Tuneable)...4- I-E96-D iii

5 Table of Contents (continued) Page SECTION 4 - CONFIGURATION (continued) Block 4, PC Communication Time Out (Milliseconds, FC 5, Non Tuneable) Block 4, PC Bad Quality Trigger Point Block (FC 9, Non Tuneable) Block 4, Number of Retries (FC 5, Non Tuneable) DIGITAL READ GROUP Block 46, First Function Block Number (FC 5, Non Tuneable) Block 47, Module Number for AB PLC- and PLC-5/50 or Function Number for Modbus RTU (FC 5, Non Tuneable) Block 48, File Type for AB PLC- or PLC-5/50 (FC 5, Non Tuneable) Block 49, File Number for AB PLC-, PLC-5 or PLC-5/50 (FC 5, Non Tuneable) Block 50, PC Memory or File Word Offset (FC 5, Non Tuneable) Block 5, Group Size (FC 5, Non Tuneable) DIGITAL WRITE GROUP Block 54, First Function Block Number (FC 5, Non Tuneable) Block 55, Module Number for AB PLC- and PLC-5/50 or Function Number for Modbus RTU (FC 5, Non Tuneable) Block 56, File Type for AB PLC- or PLC-5/50 (FC 5, Non Tuneable) Block 57, File Number for AB PLC-, PLC-5, PLC-5/50 (FC 5, Non Tuneable) Block 58, PC Memory or File Word Offset (FC 5, Non Tuneable) Block 59, Group Size (FC 5, Non Tuneable) ANALOG READ GROUP Block 6, First Function Block Number (FC 5, Non Tuneable) Block 6, Module Number for AB PLC- and PLC-5/50 or Function Number for Modbus RTU (FC 5, Non Tuneable) Block 64, File Type for AB PLC- or PLC-5/50, (FC 5, Non Tuneable) Block 65, File Number for AB PLC-, PLC-5, PLC-5/50 (FC 5, Non Tuneable) Block 66, PC Memory or File Word Offset (FC 5, Non Tuneable) Block 67, Group Size (FC 5, Non Tuneable) ANALOG WRITE GROUP Block 70, First Function Block Number (FC 5, Non Tuneable) Block 7, Module Number for AB PLC- and PLC-5/50 or Function Number for Modbus RTU (FC 5, Non Tuneable) Block 7, File Type for AB PLC- or PLC-5/50 (FC 5, Non Tuneable) Block 7, File Number for AB PLC-, PLC-5, PLC-5/50 (FC 5, Non Tuneable) Block 74, PC Memory or File Word Offset (FC 5, Non Tuneable) Block 75, Group Size (FC 5, Non Tuneable) STATISTICS Block 80, Rolling Average PC Turnaround Time (FC 7 No Settable Specifications. Four Outputs. Blocks ) Block 8, Rolling Average Read/Write Cycle Time Block 8, PC Status Block 8, PC Communications Time-out Count Block 84, PC Error Count (FC 7, No Settable Specifications. Four Outputs. Blocks ) Block 85, PC Last Error Block 86, Link Status Block 87, PCC0 Link Serial Communication Port Status Block 88, Block I/O Error Count (FC 7, No Settable Specifications. Four Outputs. Blocks ) INVOKE C, THE COMMUNICATION PROGRAM Block 99 Invoke 'C' Block THE RECOMMENDED SECOND SEGMENT Block 00 Segment Control Block (Recommended) iv I-E96-D

6 Table of Contents (continued) Page SECTION 4 - CONFIGURATION (continued) APPLICATION CONFIGURATION PC I/O Function Blocks Digital Read Group Digital Write Group Analog Read Group Analog Write Group SCALING AND OFFSET CONVERSION PASSING DATA VALUE QUALITY TO THE CONTROLLER PASSING DATA VALUE QUALITY FROM THE CONTROLLER Analog Digital SETTING UP SYSTEM HEARTBEAT MONITORING MFP0 FUNCTION CODES NOT AVAILABLE IN THE IMPCC PROGRAMMABLE CONTROLLER DATA PREPARATION...4- GENERAL APPLICATION RECOMMENDATIONS...4- SECTION 5 - TROUBLESHOOTING NORMAL OPERATION...5- MODULE (HARD) ERRORS...5- PCC0 CONFIGURATION/COMMUNICATION ERRORS...5- THE PROBLEM REPORT FORM...5- REMOTE ERROR MONITORING APPENDIX A - ERROR CODES AND MESSAGES...A- LED ERROR CODES... A- DIAGNOSTIC ERROR MESSAGES... A- STATUS MESSAGES... A- PC I/O BLOCK ERROR MESSAGES... A-4 PCC0 GENERAL STATUS MESSAGES... A-5 MODBUS (RTU) SPECIFIC ERROR MESSAGES... A-5 ALLEN-BRADLEY SPECIFIC ERROR MESSAGES... A-6 ALLEN-BRADLEY & MODBUS (RTU) COMMON ERROR MESSAGES... A-8 PCC0 MODULE SERIAL PORT ERROR MESSAGES... A-9 APPENDIX B - PROBLEM REPORT FORM...B- REPORTING A PROBLEM... B- APPENDIX C - BASE FUNCTION BLOCK CONFIGURATION...C- SPECIFICATION LEGAL RANGES... C- BASE FUNCTION BLOCK CONFIGURATION DRAWINGS... C- APPENDIX D - JUMPERS AND CABLE CONFIGURATIONS...D- GENERAL INFORMATION... D- ALLEN-BRADLEY SERIES B 77-KG COMMUNICATION ADAPTER (770-CG)... D- ALLEN-BRADLEY SERIES B 77-KG COMMUNICATION ADAPTER (CUSTOM)... D-4 ALLEN-BRADLEY 770-KF COMMUNICATION ADAPTER... D-6 MODICON 984/8 MODBUS PORT CONNECTION... D-8 I-E96-D v

7 Table of Contents (continued) Page APPENDIX D - JUMPERS AND CABLE CONFIGURATIONS (continued) IBM PC WORKSTATION SERIAL PORT CONNECTION TO MONITOR PORT (NTMP0)...D-0 IBM PC WORKSTATION SERIAL PORT CONNECTION TO MONITOR PORT (NIMP0/0)...D- TELEPHONE MODEM CONNECTION TO MONITOR PORT (REMOTE MONITORING)..D-4 ALLEN-BRADLEY 77-KG COMMUNICATION ADAPTER (MODEM)...D-6 vi I-E96-D

8 List of Figures No. Title Page -. Terminal Keyboard Interactive Facility Data Groups Transferred by PCC PCCO Capacity Charts Examples of Digital Read Group PC I/O Function Blocks Examples of Digital Write Group PC I/O Function Blocks Examples of Analog Read Group PC I/O Function Blocks Examples of Analog Write Group PC I/O Function Blocks Combining Analog Value and Quality in Function Blocks Combining Digital Value and Quality in Function Blocks Heartbeat Source Signal in Function Blocks Sensing PLC Heartbeat Signal in Function Blocks Diagnostic Output Menu ERR_VIEW User Menu...5- C-. Base Blocks 0 through 4, Communication Specifications... C-4 C-. Base Blocks 46 through 75, Data Groups... C-5 C-. Base Blocks 80 through 99, Statistics and Invoke C... C-6 C-4. Base Blocks 00, Recommended nd Segment Control Block... C-6 C-5. Digital Read and Write I/O Blocks Examples... C-7 C-6. Analog Read and Write I/O Blocks Examples... C-8 C-7. Function Block Derived Write Enable and Data Quality... C-9 D-. Allen-Bradley 77-KG Communication Adapter (770-CG) Jumper Settings... D- D-. Allen-Bradley 77-KG Communication Adapter (770-CG) Cabling... D- D-. Allen-Bradley Series B 77-KG Typical Switch Setting... D- D-4. Allen-Bradley 77-KG Communication Adapter (Custom) Jumper Settings... D-4 D-5. Allen-Bradley 77-KG Communication Adapter (Custom) Cabling... D-5 D-6. Allen-Bradley 77-KG Typical Switch Settings... D-5 D-7. Allen-Bradley 770-KF Communication Adapter Jumper Settings... D-6 D-8. Allen-Bradley 770-KF Communication Adapter Cabling... D-7 D-9. Allen-Bradley 770-KF Typical Switch Settings... D-7 D-0. Modicon 984/8 Modbus Port Connection Jumper Settings... D-8 D-. Modicon 984/8 Modbus Port Connection Cabling... D-9 D-. IBM PC Serial Port Connection to Monitor Port (NTMP0) Jumper Settings... D-0 D-. IBM PC Workstation Serial Port Connection to Monitor Port (NTMP0) Cabling... D- D-4. IBM PC Workstation Serial Port Connection to Monitor Port (NIMP0/0) Jumper Settings... D- D-5. IBM PC Workstation Serial Port Connection to Monitor Port D-6. (NIMP0/0) Cabling... D- Telephone Modem Connection to Monitor Port (Remote Monitoring) Jumper Settings... D-4 D-7. Telephone Modem Connection to Monitor Port (Remote Monitoring) Cabling... D-5 D-8. Allen-Bradley 77-KG Communication Adapter (Modem) Jumper Settings... D-6 D-9. Allen-Bradley 77-KG Communication Adapter (Modem) Cabling... D-7 I-E96-D vii

9 List of Tables No. Title Page -. Allen-Bradley PLCs Supported PCs With Support For Modbus (RTU) Protocol Hardware Requirements Capacity Specifications Related Documents Frequently Used Terms Block 0, PC Device Type Option Serial Communication Port Parameters MFP0 Function Codes Not Available in the IMPCC A-. LED Error Codes... A- A-. Diagnostic Error Messages...A- A-. Status Messages... A- A-4. PC I/O Block Error Messages... A-4 A-5. PCC0 General Status Messages... A-5 A-6. Modbus (RTU) Specific Error Messages... A-6 A-7. Allen-Bradley Specific Error Messages... A-6 A-8. Allen-Bradley & Modbus (RTU) Common Error Messages... A-8 A-9. PCC0 Module Serial Port Error Messages... A-9 C-. Base Function Block Specifications Legal Ranges...C- D-. Allen-Bradley Series B 77-KG Communication Adapter (770-CG)...D- D-. Allen-Bradley 77-KG Communication Adapter (770-CG) Cabling...D- D-. Allen-Bradley Series B 77-KG Communication Adapter (Custom)...D-4 D-4. Allen-Bradley 77-KG Communication Adapter (Custom) Cabling...D-5 D-5. Allen-Bradley 770-KF Communication Adapter...D-6 D-6. Allen-Bradley 770-KF Communication Adapter Cabling...D-7 D-7. Modicon 984/8 Modbus Port Connection...D-8 D-8. Modicon 984/8 Modbus Port Connection Cabling...D-9 D-9. IBM PC Workstation Serial Port Connection to Monitor Port (NTMP0)...D-0 D-0. IBM PC Workstation Serial Port Connection to Monitor Port (NTMP0) Cabling...D- D-. IBM PC Workstation Serial Port Connection To Monitor Port (NIMP0/0)...D- D-. IBM PC Workstation Serial Port Connection to Monitor Port (NIMP0/0) Cabling...D- D-. Telephone Modem Connection To Monitor Port (Remote Monitoring)...D-4 D-4. Telephone Modem Connection to Monitor Port (Remote Monitoring) Cabling...D-5 D-5. Allen-Bradley 77-KG Communication Adapter (Modem)...D-6 D-6. Allen-Bradley 77-KG Communication Adapter (Modem) Cabling...D-7 viii I-E96-D

10 Safety Summary SPECIFIC CAUTIONS Always use Elsag Bailey's Field Static Kit (P/N 94885A - consisting of wrist strap, ground cord assembly, alligator clip) when working with modules. The kit connects a technician and the static dissipative work surface to the same ground point to prevent damage to the modules by electrostatic discharge. (p. -) Time critical closed loop control and interlocks should not be implemented via this link without first performing tests with the complete INFI 90 OPEN and PC device systems to account for the asynchronous nature of the PC device scan cycle with respect to the PCC0 cycle. (p. 4-4) Some Modbus protocol PC devices may limit the number of bytes to a number less than 00. See particular manufacturers manuals for details. (p. 4-4) I-E96-D ix

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12 SECTION - INTRODUCTION OVERVIEW The Programmable Controller Coupler module IMPCC0 is a Elsag Bailey module designed specifically to interface the Elsag Bailey INFI 90 OPEN system to a Programmable Controller (PC) system. The module can be set up to use either Allen-Bradley DF or Modbus (RTU mode) protocol via RS serial communication. All controllers with support for Modbus functions,,,4,5, and 6 or Allen Bradley PLC-, PLC-, PLC-5, and PLC-5/50 are supported. Support for Allen Bradley includes both Data Highway/Data Highway Plus and Data Highway II. The IMPCC0 module has an optically isolated RS port that either connects directly to the controller or connects to a device that provides access to the controller. The IMPCC0 communicates with a single PC device to pass a preset amount of data to pre-defined contiguous areas of the PC's memory and reads a preset amount of data from pre-configured contiguous areas of the PC's memory. Every point included in the pre-defined areas is read from or written to the PC device once a second. The IMPCC0 module limits the amount of data transferred between the module and the PC device to 00 bytes in each direction. The 00 bytes read from the device can consist of up to 04 discrete digital or 00 analog values or any combination thereof not exceeding the 00 byte limit. The 00 bytes written to the device can consist of up to 5 discrete digitals or 00 analog values or any combination thereof not exceeding the 00 byte limit. NOTE: One analog value consists of bytes of data. Eight discrete digital values form byte of data. The latest status and performance report messages are available via the Monitor port, the second RS port, on the IMPCC0 termination unit/module. Module, link and communication status information is also available in I90 block output and the LEDs on the faceplate of the module. Module redundancy is available with the IMPCC0. Serial link redundancy is not supported. PROGRAMMABLE CONTROLLERS SUPPORTED The PCC0 module supports the following Allen-Bradley devices when interfaced via the appropriate communication adapter. OVERVIEW I-E96-D -

13 INTRODUCTION Programmable Controller Model Table -. Allen-Bradley PLCs Supported Data Highway Model Communication Adapter Model PLC- None 77-KG I 77-KE/KF, 770-KF Plus 770-KF or 785-KE and 785-KA II 779-KFL/KFLR and 779-KP PLC- None I 77-KE/KF, 770-KF Plus 770-KF or 785-KE and 785-KA II 779-KFL/KFLR and 779-KP PLC-5 None I 77-KE/KF or 770-KF and 785-KA Plus 770-KF, 785-KE II 779-KFL/KFLR and 779-KP5 PLC-5/50 None I 77-KE/KF or 770-KF and 785-KA Plus 770-KF, 785-KE II 779-KFL/KFLR and 779-KP5 The PCC0 module supports the following Modbus protocol devices when connected via the appropriate communication adapter. Table -. PCs With Support For Modbus (RTU) Protocol Programmable Controller (PC) Model Modicon 584 Modicon 984 GE Series-5 GE Series-6 GE Series 9070 Siemens S5 Reliance Other (Standard Modbus RTU) Modbus (RTU) Communication Adapter Supporting Functions,,, 4, 5 and 6 Direct connect via Modbus port. Direct connect via Modbus port. CCM. CCM. PCM, CMM. CP54, CP55. Access must support Modbus (RTU) functions,,, 4, 5 and 6. PROGRAMMABLE CONTROLLERS SUPPORTED - I-E96-D

14 INTRODUCTION HARDWARE NEEDED TO SUPPORT THE IMPCC0 Table -. Hardware Requirements Hardware Nomenclature/Part No. Programmable controller coupler IMPCC0. module Termination module or Termination unit Cables: PCC to termination unit cable or PCC to termination module cable NIMP0/0 or NTMP0. NKTU0 or NKTU0. PCC termination to foreign device serial cable Device dependent cable. MEMORY AND TIME RESPONSE CAPACITY SPECIFICATIONS Table -4. Capacity Specifications Specification Value Comments User available Non-Volatile RAM (kbytes) 60 User available Volatile RAM (kbytes) 60 Maximum Read data transfer capacity (Bytes) 00 Total number of analog plus digital data bytes input from the programmable controller. Maximum Write data transfer capacity (Bytes) 00 Total number of analog plus digital data bytes output to the programmable controller. Maximum number of discrete digital bit values input (Read) from the programmable controller Maximum number of analog, 6 bit integer, values input (Read) from the programmable controller. Maximum number of discrete digital bit values output (Written) to the programmable controller. Maximum number of analog, 6 bit integer, values output (Written) to the programmable controller. Bi-directional all point update rate (seconds) digital bit values at 8 bits/byte require 8 input bytes leaving 7 bytes for 6 analog inputs analog, 6 bit integer, values require 00 input bytes leaving no capacity for digital inputs. 5 5 digital bit values at 8 bits/byte require 64 output bytes leaving 6 bytes for 68 analog outputs analog, 6 bit integer, values require 00 output bytes leaving no capacity for digital outputs. All up to 00 input data bytes are transferred from the programmable controller, de-multiplexed and are written to function blocks once a second. All up to 00 output data bytes are updated from function blocks and are written to the programmable controller once a second. SOFTWARE SUPPLIED ON THE DISKETTE INCLUDED WITH THE IMPCC0. A base function block configuration. HARDWARE NEEDED TO SUPPORT THE IMPCC0 I-E96-D -

15 INTRODUCTION The base function block configuration consists of Elsag Bailey CADEWS drawing files. These drawings depict a typical base function block configuration for a PCC0 application which can, if desired, be modified to include the user specific block configuration. The drawings are shown in Appendix C.. A terminal program to view the error log output. The terminal program is an MS-DOS program that may be used to view the status and performance messages output from the Monitor port, the second RS serial communication port.. A non-volatile error log viewer program. The error log viewer is an MS-DOS program that requires a SPM, CPM or CIU interface to upload the error file. CONTENT OF THIS MANUAL This manual is intended to be used as a guide and reference for users of the PCC0 module. It includes instructions for configuring and installing the module (hardware dip switches and TU jumpers) and for entering the base block configuration required to set up communication with the user s programmable controller. It is assumed the user has some familiarity with the Elsag Bailey INFI 90 OPEN system and the programmable controller. RELATED DOCUMENTS Table -5. Related Documents Document Number I-E96-00 I-E96-40 I-E96-48 I-E96-0 Document Title Function Code Application Manual. NIMP0/0 Termination Module. NTMP0 Termination Unit. IMMFP0 Module. CONTENT OF THIS MANUAL - 4 I-E96-D

16 INTRODUCTION FREQUENTLY USED TERMS Table -6. Frequently Used Terms Term PC PC Device PC I/O Function Blocks Communication Port Monitor Port Explanation Programmable Controller. The user's specific Programmable Controller. The function blocks associated with the read/write groups to source and receive the programmable controller data. The port marked PRINTER on the termination unit or module. The port marked TERMINAL on the termination unit or module. FREQUENTLY USED TERMS I-E96-D - 5

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18 SECTION - DESCRIPTION OVERVIEW The PCC0 module can be set up to communicate with an Allen-Bradley PLC-, PLC-, PLC-5 or PLC-5/50 using Data Highway, Data Highway Plus or Data Highway II protocol. It can also be set up to communicate with a Modicon 584 or 984 programmable controller using Modbus (RTU mode) protocol or to one of the many other controllers that have support for Modbus (RTU mode) protocol communication. All software setup for communication with a particular controller consists of setting the specifications of the base function blocks, blocks 0 through 99 of the module and can be accomplished with CADEWS (see Section 4 - CONFIGURATION). The PCC0 performs up to four (4) data transactions with the programmable controller. One digital data read transaction. One digital data write transaction. One analog data read and one analog data write transaction. Each transaction is for a contiguous data group for which a contiguous number of function blocks are associated with a contiguous number of data cells in the controller. The performance goal for this module is to read every read point and write every write point included in the digital and analog groups every second. In order to meet this goal the module is designed to address a single controller and to limit the total amount of data that can be read from this controller to 00 data bytes and to limit the total amount of data that can be written to this controller to 00 data bytes. To help in identifying configuration errors and communication faults, the PCC0 program includes the facility to output a limited number of performance statistics and to report errors detected in the setup block specifications and communications. The performance statistics are output to function blocks 80 through 88. Detected errors are output in three different ways. In an encoded form displayed on the module front plate LEDs. As unique time stamped text messages output to a file in the non-volatile RAM of the module. As unique time stamped text messages output to the Monitor port (RS terminal port) of the module. The error messages directed to the Monitor port are, initially, written to a volatile RAM buffer. Output to the Monitor port must be enabled via a base function block specification, block number 8. A terminal or terminal OVERVIEW I-E96-D -

19 DESCRIPTION emulator must be connected to the PCC0's Monitor port to view the error output. Figure - shows the simple terminal keyboard interactive facility that has been provided for buffer maintenance and output selection. Copyright (c) Elsag Bailey (Canada) Inc., 99 D - Delete all error messages P - Pause C - Continue after pause S - Start from the beginning W - Wrap mode N - No wrap mode?,h - Help Press any of the above keys Figure -. Terminal Keyboard Interactive Facility GENERAL INFORMATION The PCC0 module must be set up appropriately for the Module Bus or ControlWay mounting rack and the plant loop or INFI 90 OPEN loop before any block configuration is entered. See Section - HARDWARE INSTALLATION AND SETUP to prepare the module. The data that is read from and written to the programmable controller is divided into 4 groups; A digital read group (DR). A digital write group (DW). An analog read group (AR). An analog write group (AW). The module setup blocks, referred to as the Base Block Configuration, includes specifications for defining each group including: The PC Memory or File Word Offset to the first PC value for the group. The application function block configuration starting block number for the group. The group size. (See BASE BLOCK CONFIGURATION in Section 4 for details). The PCC0 performs a transaction for each of the groups for which the size is greater than zero. If for example analog writes are not required, the analog write group size must be set to zero so no analog write transaction will be performed. The PCC0 module uses block read and block write commands to exchange data with the PC device. As such, the data points for each group must be allocated contiguous locations GENERAL INFORMATION - I-E96-D

20 DESCRIPTION in the PC device and must correspondingly be assigned contiguous block numbers in the module's application function block configuration. This allows the PCC0 program to associate groups of data read from the PC device with groups of block numbers in the PCC0 module on a one to one basis in sequential order. TRANSACTION DATA FIELD SIZE DETERMINATION The data field of the digital read and write commands are calculated by the PCC0 program to be in word increments (6 bit words). If the defined PC Memory or File Word Offset to the first point of a group does not correspond to the low order bit of a word, and/or the Group Size is not evenly divisible by 6, then the calculated data field size is rounded out to the required number of words to include all points. NOTE: The calculated data field size for the Digital Write Group transaction is the rounded out number of words of data. PROGRAMMABLE CONTROLLER ANALOG DATA FORMAT/CONVERSION Base Block Configuration block number 9, PC Register Value Format, is a global definition for all analog read and write points. It defines all programmable controller analog type values to be unsigned binary integers, signed binary integers, unsigned bit BCD integers or 6 bit BCD integers. The only data conversion performed by the PCC0 communication firmware program is to convert between the defined controller analog data format and the floating point real format of analog data blocks. Any required Scale and Offset conversions of analog values may be added to the application function block configuration for the module (see APPLICATION CONFIGURA- TION in Section 4). DIGITAL AND ANALOG WRITE GROUPS INITIAL DATA When the module is put into execute the digital and analog write areas in the PC are initially read and stored in an area of the PCC0 module's volatile RAM to become the initial values for the write points. If any of the points in the range of the write groups have no function block defined in the application function block configuration or have a function block of the wrong output type, then the initial values for these points are used for the write transactions to the PC device. Any data values written locally into the PC file locations for the write group are overwritten by the PCC0 (see the notes in Block 7, Write Permissive (FC 9, Non Tuneable) in Section 4). TRANSACTION DATA FIELD SIZE DETERMINATION I-E96-D -

21 DESCRIPTION WRITE GROUP BLOCK OUTPUT BAD QUALITY HANDLING If any of the application function block outputs associated with the write groups go to bad quality, the last good quality values read from these blocks, which are maintained in the module volatile RAM memory, are re-written to the PC device until the blocks return to good quality. If no good quality value has been read for some or all points of a write group since the module was reset or powered up, then the initial values read from the PC device during the startup phase will be written back to the PC device for these points. REDUNDANT MODULES STANDBY TAKEOVER In redundant PCC0 module configurations, the primary PCC0 module executes the application function block configuration and performs communication with the PC device. The block output values of the standby PCC0 are updated from the primary PCC0 by the Elsag Bailey standard redundancy checkpointing mechanism. When a switchover to the redundant standby module occurs, communication is re-established with the PC device as for a cold start except that all the block output values and qualities are retained from the primary module by the checkpointing mechanism. ERROR REPORTING METHODS The IMPCC0 module is a modified IMMFP0 module. As such its performance can be monitored using the standard Elsag Bailey tools, CADEWS, CLS, the operator stations OIS-0/0/ 0/40, etc. The PCC0 module provides additional error reporting. It detects a multitude of configuration and communication errors. These errors are reported in the following three different ways:. They are displayed in numerically encoded form on the LEDs of the module face plate (see Table A- for error interpretation). Under these conditions, the module remains in the Execute mode with the status LED solid green. The additional error codes are displayed in flashing red in LEDs through 6 while LEDs 7 and 8 remain solid red.. They are written as unique text messages to a circular volatile RAM buffer. The errors in this buffer may be output to the module Monitor (terminal) port when a terminal has been connected to this port and output has been enabled via base block number 8, Diagnostic Output Enable (see BASE BLOCK CONFIGURATION in Section 4 and Appendix A - ERROR CODES AND MESSAGES). The errors recorded in the volatile RAM buffer are lost when the PCC0 module is reset, when power is removed or after a switchover to the redundant standby module. WRITE GROUP BLOCK OUTPUT BAD QUALITY HANDLING - 4 I-E96-D

22 DESCRIPTION. They are written as unique text messages to the Diagnostic Error file, a non-volatile RAM file. The errors written to the Diagnostic Error file must be retrieved via a Serial Port Module (SPM), a Communication Port Module (CPM) or a Computer Interface Unit (CIU) module set and the error viewing program included on the diskette provided with the PCC0 module. The errors written to the non-volatile RAM file are lost only when the PCC0 module is initialized, a manual operation. The Diagnostic Error file is relatively large (6 Kbytes) but wraps around once full to overwrite the oldest messages. To view error messages that were generated prior to a switchover to the standby module of a redundant module set, the messages must be retrieved from the Diagnostic Error file. The text messages have been defined with care to ensure that configuration and communication faults are described as clearly as possible. For a description of all messages, see Appendix A - ERROR CODES AND MESSAGES. ERROR REPORTING METHODS I-E96-D - 5

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24 SECTION - HARDWARE INSTALLATION AND SETUP GENERAL INFORMATION This section explains what you must do before any function block configuration is attempted. The steps performed to initialize the module will clear all current content of the non-volatile and volatile RAM and thus any configuration existing in the module will be cleared. NOTES:. This module uses connections to the MMU backplane that served other functions in early Network 90 systems. To avoid module damage, the system must be checked for compatibility prior to module installation.. Early Network 90 systems applied -0 VDC to pins and 4 of the module connector P. This voltage is not required for INFI 90 OPEN modules. In INFI 90 OPEN systems, pins and 4 are used for the redundant Controlway bus.. If your system has modules that require -0 VDC, you must set J5 to the 0 VDC position. Doing so allows you to install the PCC0 in a MMU that uses -0 VDC. Refer to manual I-E96-0, Table -6 for more information about setting J5. CAUTION Always use Elsag Bailey's Field Static Kit (P/N 94885A - consisting of wrist strap, ground cord assembly, alligator clip) when working with modules. The kit connects a technician and the static dissipative work surface to the same ground point to prevent damage to the modules by electrostatic discharge. To set up the module and termination unit hardware refer to the following Product Instructions: Multi-Function Processor Module (IMMMFP0) I-E96-0 and Multi-Function Processor Termination Unit (NTMP0) I-E96-48 or Multi-Function Processor Termination Modules (NIMP0/ 0) I-E The IMPCC0 module jumpers J through J4 must not be changed from factory settings. The 8 position dipswitches must be set for your application according to manual I-E96-0, Section - INSTALLATION. Their particular settings configure the module for Controlway/Module Bus, redundancy, Enable/Disable On-Line Configuration and Enable/Disable memory checksumming self diagnostics. All of these selections must be made before the module is installed for normal operation. GENERAL INFORMATION I-E96-D -

25 HARDWARE INSTALLATION AND SETUP PCC0 MODULE INITIALIZATION Next the module must be initialized for either plant loop or INFI 90 OPEN by the following special operations steps. Again see manual I-E96-0, Section - INSTALLATION, Special Operations for more detail.. Remove the PCC0 module from the Module Bus or Controlway mounting rack and set (open) SW4 switches and 7. All other switches of SW4 must be reset (closed). Re-insert the module in the mounting rack. Wait until the module red lights with LEDs through 6 on. The module RAM has been initialized and the module has been setup for plant loop.. If the module is to be installed for INFI 90 OPEN, remove the module again and set switches and 6. All other switches of SW4 must be reset (closed). Re-insert the module in the mounting rack. Wait until the module red lights with LEDs through 6 on.. Remove the module from the rack again and restore the required run time setting for SW4. 4. Re-insert the module in the mounting rack. The memory of the module has now been initialized. The base blocks and application configuration should now be loaded to make the module ready for communicating with the PC device. SERIAL RS SIGNAL TERMINATION Modems are not required for isolation. Isolation is built into the serial port NTMP0 Termination Unit and NIMP0/0 Termination Module. Modems will be needed for communication over distances exceeding 50 feet. The termination unit/module jumpers must be set to satisfy the programmable controller's RS serial communication DTE/DCE and handshaking characteristics. Refer to Section - INSTALLATION in your Multi-Function Processor Termination Unit (NTMP0) manual or Section - Installation of your Multi-Function Process Termination Module (NIMP0/0) manual for details on each of the jumpers. The Communication port (marked Printer on the termination unit or module) must be connected to the PC device. The Monitor port (marked Terminal) may be connected to a terminal. PCC0 MODULE INITIALIZATION - I-E96-D

26 SECTION 4 - CONFIGURATION GENERAL INFORMATION The module blockware must be configured for the user's specific programmable controller system and application function block logic. Refer to the example drawings in Appendix C - BASE FUNCTION BLOCK CONFIGURATION. The CADEWS files for these drawings are on the diskette provided with the IMPCC0 module. FUNCTION BLOCKS The PCC0 module function block configuration consists of two parts. The first part makes up the base block configuration and includes function blocks 0 through 99. The second part is the application configuration and includes function blocks 00 through The CADEWS configuration included on the diskette supplied with the module contains the required base blocks. This file may be used as a starting point for the user's specific configuration for the PCC0 module if desired. The base block area contains the function blocks that define the communication parameters for the PCC0 module. All function blocks of the base block configuration must be setup for the programmable controller characteristics and the data to be exchanged. Missing blocks or invalid setup values for any of the blocks will cause errors and will inhibit module operation. The application configuration must contain the function blocks for the data to be written to the programmable controller and the data to be received from the programmable controller plus any additional logic function blocks and slave I/O function blocks. The location and the number of programmable controller I/O data function blocks must correspond to the parameters set up in the base block configuration. For the PC I/O function blocks into which the data read from the programmable controller is stored, the choice of function codes is limited as follows: (see also Figures 4- and 4-5). Analog (Register) Values Digital (Discrete) Values function code 7, Basic Real Output with Quality. function code 0, Analog Exception Report. function code 8, Basic Boolean Output with Quality. function code 45, Digital Exception Report. For the PC I/O function blocks, from which the data to be written to the programmable controller is obtained, any function GENERAL INFORMATION I-E96-D 4 -

27 CONFIGURATION code with the proper output type may be assigned with the following exception (see also Figures 4-4 and 4-6).. Since all block outputs in the PC I/O write group (digital write or analog write group) must be of the same type, function codes with multiple outputs of mixed type can not be used.. If source values for a group are scattered, it is recommended that buffer blocks be set up to collect the values for a group in one contiguous set of block outputs. Example Example -Input OR blocks, function code 9, may be used to bring together all point values for the digital write group. -Input Summer blocks, function code 5, or Analog Transfer blocks, function code 9, may be used to bring together the point values for the analog write group. Note that the function code 5 specifications allow the block output value to be scaled before it is written to the PC. SETTING UP THE DATA TRANSFER GROUPS The coupler allows up to two read groups and up to two write groups. See Figure 4-. The groups are referred to as follows: DW digital write (output to PC device). DR digital read (input from PC device). AW analog write (output to PC device). AR analog read (input from PC device). The read and write groups are contiguous areas of memory in the PC device and consecutive function block numbers in the PCC0 module. As mentioned in a preceding section, there should only be analog output blocks within the analog write group PC I/O block range, only digital output blocks within the digital write group PC I/O block range, function codes 0 or 7 blocks within the analog read group PC I/O block range and only function codes 45 or 8 blocks within the digital read group PC I/O block range. SETTING UP THE DATA TRANSFER GROUPS 4 - I-E96-D

28 CONFIGURATION Figure 4-. Data Groups Transferred by PCC0 Data Link Boundaries The selected baud rate must be 9600 or faster and the PC device response time 50 ms or less, for the coupler to read and write every configured digital and analog point from/to the PC device once every second. The PCC0 communication with the PC device occurs asynchronous with the function block execution and the PC device program execution. That is, the one second cycle for passing all data between the PC device memory and the PCC0 function blocks occurs asynchronous to any change of state occurring on either side of the data communication link. As such, the time to report a change of state in the PCC0 function blocks to the PC device memory or a change of state in the PC device memory to PCC0 function blocks will vary from less than second to a maximum of seconds. SETTING UP THE DATA TRANSFER GROUPS I-E96-D 4 -

29 CONFIGURATION Figure 4-. PCCO Capacity Charts CAUTION Time critical closed loop control and interlocks should not be implemented via this link without first performing tests with the complete INFI 90 OPEN and PC device systems to account for the asynchronous nature of the PC device scan cycle with respect to the PCC0 cycle. SETTING UP THE DATA TRANSFER GROUPS 4-4 I-E96-D

30 CONFIGURATION Analog values (register values) in the PC are treated by the PCC0 as signed or unsigned6 bit integers, unsigned 6 bit BCD integers or unsigned bit BCD integers depending on the global specification entered in block number 9 of the Base Block Configuration. Zero and span conversion of analog values may be performed within the user's function block configuration (see APPLICATION CONFIGURATION as well as SCALING AND OFFSET CONVERSION). The PCC0 module capability to interface to I90 slave modules is approximately equivalent to that of the MFP0 module. To limit time utilization for slave module I/O, it is recommended that the amount of slave module I/O be limited to 7 slave modules. Critical PCC0 Configuration Run Time Considerations Block numbers 0 through 99 are exclusively used for the PCC0 module communication setup and are referred to as the Base Block Configuration. Each of the base blocks must be configured to match the programmable controller being interfaced to. These blocks reside in segment # whose execution run time parameters reside in the segment control function block (function code 8) at block number 5. Its segment priority must be set to 55 (the highest possible). Block numbers 00 to 9998 must contain the PC I/O data blocks and are further available for user logic and for slave module I/O function blocks. It is recommended that block number 00 be made another segment control block to allow the run time parameters for the blocks above 00 to be set different and independent from the PCC0 program in segment #. The CADEWS Base Block Configuration files on the diskette supplied with the module have the priority specification for the Segment Control blocks at block numbers 5 and 00 already set up. Refer to BASE BLOCK CONFIGURATION for detail. PC Data Addressing The PC data addressing must be set up to accommodate the user's PC device. Not all address fields are required for all PC types. If these fields are not required the PCC0 module requires that the user set such values to 0. Each of the 4 groups (digital read, digital write, analog read, analog write) must have its address locations individually and completely set up in the Base Block Configuration. A general description of the addressing conventions for the different programmable controller types is provided in the following paragraphs: Allen-Bradley PLC For PLC 's, data is referenced only with absolute word addresses. The accepted range is from 0 to 999. The address fields for module number/command number, file type and file SETTING UP THE DATA TRANSFER GROUPS I-E96-D 4-5

31 CONFIGURATION number are unused and must be set to 0. Each of the 4 groups can access any area within the legal range for the PLC. IMPCC0 applies the Block Check Character (BCC) and not the Cyclic Redundancy Check (CRC) for data verification. Allen-Bradley PLC For PLC, PCC0 always addresses data tables, logically defined partitions of the physical memory of the controller. The accepted address range within the tables is 0 to 999. Each of the 4 groups can access any area within the accepted address range of the tables. The module number/command number field refers to the PLC context. A value of 0 defined for the context means the location specified within the PLC as default for context will be the context area addressed. It is recommended to use the addressed context explicitly (range - 5). The file types (tables) supported by the PCC0 module are: output image input image 5 integer 7 decimal 8 binary status The file (table) numbers that are supported are 0 to 999. Each of the four groups can access any supported file type and file number. IMPCC0 applies the Block Check Character (BCC) and not the Cyclic Redundancy Check (CRC) for data verification. Allen-Bradley PLC 5 For PLC 5, PCC0 addresses only files. The accepted address range within each file is 0 to 999. Each of the 4 groups can access any area within the accepted file address range. The module number/command number and file type must be set to 0. The accepted range for file number is Each of the four groups can access any one of the accepted file numbers. IMPCC0 applies the Block Check Character (BCC) and not the Cyclic Redundancy Check (CRC) for data verification. SETTING UP THE DATA TRANSFER GROUPS 4-6 I-E96-D

32 CONFIGURATION Allen-Bradley PLC 5/50 For PLC 5/50 addressing, PCC0 supports module numbers 0 through 4 where 0 is the resource manager, and through 4 are logic processor module addresses as set by the thumbwheel switches. The remote scanner module is not supported. The PCC0 module accesses the data table system area only. File types (sections) 0 (binary) and (integer) are the only types (sections) supported. File numbers can range from 0 to 999. The accepted address range (number of elements) within each file is 0 to 999. The member and submember fields for addressing elements are unused and are always set to 0 by the PCC0. Each of the four groups can access any area within the accepted file address range. IMPCC0 applies the Block Check Character (BCC) and not the Cyclic Redundancy Check (CRC) for data verification. Modbus Protocol Valid modbus addresses vary between PC device types. Consult your PC device manual for valid addressing. For Modbus protocol communication the module number/ command number refers to the Modbus function. The supported functions are: read coil status read input status read holding register 4 read input register 5 force multiple coils 6 load multiple registers Function or may be specified for the digital read group, function or 4 may be specified for the analog read group depending on the PC data area to be read. For the digital write group function 5 must be assigned and for the analog write group function 6 must be assigned. The file type and file number are not used and must be set to 0. IMPCC0 supports the Modbus RTU mode only. It does not support Modbus ASCII mode. SETTING UP THE DATA TRANSFER GROUPS I-E96-D 4-7

33 CONFIGURATION BASE BLOCK CONFIGURATION Each function block in the base block configuration must be present and have its specifications defined exactly for your programmable controller. Communication will not be established if invalid entries are made. The CAD configuration supplied with the module includes all base blocks. It can be used to start off a user configuration for the PCC0. However, each block specification must be reviewed and the default value replaced with the value needed for your particular programmable controller system. After setting all the Base Block Configuration specifications, the PC data I/O interface blocks plus the user logic blocks, if any, must be configured as required for your application. If errors exist in the base block specifications when the module is loaded and placed in execute, error messages will appear in the error file and at the diagnostic port (if it has been enabled). NOTE: All non-boolean function block specifications must be entered as decimal values. Some Allen-Bradley addressing parameters may be defined in octal in Allen-Bradley publications and these will require conversion to decimal for the Base Block Configuration specifications. COMMON COMMUNICATION DEFINITIONS Block 5, Segment Control Block Critical specifications for this block: S = (time in seconds). S = 0. (cycle time). S = 55 (priority). S The target period must be set to 0. seconds for the module to read and write each point once a second. The module has two read and two write commands to send to the PC device. One command is sent per target period (0. seconds) with one target period left to take care of any late transactions. Increasing this value will slow down communications to the PC device. Decreasing this value may slightly increase the communication rate but may also decrease the module free time (block output). If the freetime is reduced to less than 5%, there may not always be enough time each and every cycle to complete execution of the application configuration in blocks 00 and higher. For installations with redundant modules, the checkpointing procedure whereby the standby module data is kept up to date may not consistently be completed. The standby checkpointing procedure is performed during the module free time remaining after the function block configuration for all segments has been executed. BASE BLOCK CONFIGURATION 4-8 I-E96-D

34 CONFIGURATION S The segment priority must be set to 55 (the highest priority) and segment # must be the only segment with the highest priority value. The PCC0 firmware has been designed around its highest priority advantage to ensure that the segment is executed every 0. seconds. No other segment can interrupt it. If another segment is running when it is time for segment # to run, this other segment will be interrupted to allow the data transfer schedule to be maintained. Block 0, PC Device Type (FC 5, Non Tuneable) In this block is specified the type of device that is connected to the module. From this specification the PCC0 firmware determines which protocol to use and how to address the particular device data areas. Options include: Table 4-. Block 0, PC Device Type Option Block 0 Value PLC Type Allen-Bradley PLC-U (Unprotected writes). Allen-Bradley PLC-P (Protected writes). Allen-Bradley PLC-. Allen-Bradley PLC-5. Allen-Bradley PLC-5/50. Square D SY/MAX (Future). GE Series 5. GE Series 6. GE Modicon 584. Modicon 984. Standard RTU. Siemens. Reliance. Texas Instrument (Future). For information on the PLC protected and unprotected writes see applicable PLC manual. Block, PC AB Data Highway II Link Address (FC 5, Non Tuneable) Destination data highway II link address. AB Data Highway II - Link address 0 to 55. For AB Data Highway and Data Highway Plus and for all other programmable controllers systems, this specification must be set to 0. NOTE: The value is a decimal value. COMMON COMMUNICATION DEFINITIONS I-E96-D 4-9